A header-tank assembly

ABSTRACT

The header-tank assembly includes a tank, a header a sealing element. The tank includes foot portions configured on at least one pair of opposite sides thereof. The header includes tabs configured on at least one pair of opposite sides. The tabs are crimped along fold lines configured thereon to receive the respective foot portions of the tank and configure connection between the header and the tank. The sealing element is disposed between the foot portions of the tank and the header. A notch is configured on an outside wall of each tab, wherein the notch extends along the fold line to facilitate crimping of the tabs over the respective foot portions and is visible after crimping operation.

The present invention relates to a heat exchanger, more particularly, to a header-tank assembly for the heat exchanger.

A heat exchanger generally includes a pair of spaced apart headers connected to two distant and opposite end portions of a heat exchanger core that is received inside a housing. Specifically, each of the spaced apart headers is configured with slots for receiving end portions of heat exchange tubes that along with the fins configure the heat exchanger core. Further, the pair of spaced apart headers, hereinafter referred to as headers are also connected to the end portions of the housing either by welding or brazing or any other joining process. The heat exchanger further includes a pair of heat exchanger tanks, hereinafter referred to as tanks, wherein each tank is joined to the corresponding header for configuring a sealed connection between the headers and the corresponding tanks, thereby configuring a header-tank assembly. Generally, the headers are connected to the respective tanks by crimping. The tank receives first heat exchanging fluid, often pressurized heat exchanging fluid from a first inlet, the heat exchanging fluid traverses through the heat exchange tubes and is received in the tank. The tank delivers out the first heat exchange fluid through a first outlet. The tanks are connected to the headers by crimping. The tanks in conjunction with the corresponding headers facilitate distribution of first heat exchange fluid to and collection of first heat exchange fluid from the heat exchange core. The crimping between the headers and the respective tanks is used for configuring header tank assembly for different heat exchangers such as for example, Water charge Air-cooler, radiator, condenser and evaporator. In case of Water charge Air-cooler, the housing receives second heat exchange media, for example, coolant therein and around the heat exchange tubes through at least one second inlet. The second heat exchange media or coolant is delivered out of the housing through at least one second outlet after the coolant has extracted heat from the first heat exchange fluid flowing through the heat exchange tubes.

Generally, the headers of the header-tank assembly are provided with tabs that fold along fold lines for facilitating crimping of the tabs of the headers over respective foot portions of the tanks with sealing elements disposed between the headers and the respective foot portions of the tanks. The crimping between the headers and the corresponding tanks is required to be secure in order to configure leak-proof connection between the headers and the corresponding tanks. Generally, the headers are formed of aluminum. In case the tabs of the headers are thick sectioned, comparative more crimping force is required for crimping the tabs over the respective foot portions of the tanks as compared to when the tabs are thin sectioned. The higher crimping forces may damage the tabs or the crimping tool used for crimping the tabs over the respective foot portions of the tank. The higher crimping forces may also damage the tanks, particularly, in case the tanks are of plastic material. Due to crimping of the tabs over the respective foot portions, cracks and defects may be formed over the tabs, however, these cracks and defects may go un-noticed and aggravate over time resulting in mechanical failures, thereby reducing reliability and service life of the heat exchanger.

Accordingly, there is a need for a header-tank assembly with a header having a provision for weakening the tabs along fold lines to facilitate crimping of thick sectioned tabs of the header over the foot portion of the respective tank. Further, there is a need for a header-tank assembly with header that requires comparatively less force for crimping of the tabs of the header over foot portions of the respective tank, thereby reducing chances of damage to the tabs or the crimping tool used for crimping or damage to the tanks. Furthermore, there is a need for header-tank assembly with header that not only prevents formation of cracks or defects resulting due to crimping of tabs of the header over foot portion of the respective tank but also ensures quick detection of the cracks or defects just by visual inspection, in case the cracks or defects are formed.

An object of the present invention is to provide a header-tank assembly with a header that obviates drawbacks associated with conventional headers that do not have any provision for weakening tabs along fold lines to facilitate crimping of the headers on respective tanks and as such the tabs are prone to damage, cracks and defects due to being subjected to high crimping forces during crimping.

Another object of the present invention is to provide a header-tank assembly with a header of such configuration that requires comparatively less force for crimping of tabs configured on the header over foot portions of respective tank.

Further, object of the present invention is to provide a header-tank assembly with a header of such configuration that substantially reduces forces required for crimping tabs configured on the headers over foot portion of respective tanks, thereby preventing damage to crimping tool used for crimping and extending service life of the crimping tool.

Another object of the present invention is to provide a header tank assembly with header of such configuration that prevents damage to the tank, particular tank of plastic material.

Still another object of the present invention is to provide a header-tank assembly with a header of such configuration that prevents formation of cracks or defects resulting due to crimping of tabs configured on the header over foot portion of the respective tanks.

Yet another object of the present invention is to provide a header-tank assembly with a header of such configuration that facilitates quick and easy detection of cracks or defects formed on the header just by visual inspection, in case any cracks or defects are formed.

In the present description, some elements or parameters may be indexed, such as a first element and a second element. In this case, unless stated otherwise, this indexation is only meant to differentiate and name elements which are similar but not identical. No idea of priority should be inferred from such indexation, as these terms may be switched without betraying the invention. Additionally, this indexation does not imply any order in mounting or use of the elements of the invention.

A header-tank assembly is disclosed in accordance with an embodiment of the present invention. The header-tank assembly includes a tank, a header a sealing element. The tank includes foot portions configured on at least one pair of opposite sides thereof. The header includes tabs configured on at least one pair of opposite sides. The tabs are crimped along fold lines configured thereon to receive the respective foot portions of the tank and configure connection between the header and the tank. The sealing element is disposed between the foot portions of the tank and the header. A notch is configured on an outside wall of each tab, wherein the notch extends along the fold line to facilitate crimping of the tabs over the respective foot portions and is visible after crimping operation.

Generally, at least one tab is configured on each side of at least one pair of opposite sides of the header.

Particularly, the tabs configured on each side of at least one pair of opposite sides of the header are spaced apart from each other.

Specifically, the tabs fold along the fold lines and the notches extending along top edges of the foot portions of the tank received in the respective header to define the crimped configuration of the tabs.

More specifically, the tabs in the crimped configuration thereof receives the respective foot portions of the tank such that a first portion and a second portion of the tabs connected along the notch abut against edges of the foot portions of the tank.

Generally, the thickness of each tab along the notch is reduced by 10-35 percent as compared to thickness of rest of the tab.

A heat exchanger is disclosed in accordance with an embodiment of the present invention. The heat exchanger includes a pair of spaced apart header-tank assembly connected by a plurality of heat exchanger elements, wherein a first header-tank assembly facilitates distribution of heat exchange fluid to the heat exchanger elements, whereas a second header-tank assembly disposed opposite to and spaced away from the first header-tank assembly facilitates collection of heat exchange fluid from the heat exchanger elements. The at least one of the header-tank assembly of the pair of header-tank assembly includes a tank, a header and a sealing element. The tank includes foot portions configured on at least one pair of opposite sides thereof. The header includes tabs configured on at least one pair of opposite sides thereof. The tabs are crimped along fold lines configured thereon to receive respective foot portions of the tank and configure connection between the header and the tank. The sealing element is disposed between the foot portions of the tank and the header. A notch is configured on an outside wall of each tab, wherein the notch extends along the fold line to facilitate crimping of the tabs over the respective foot portions and is visible even after the crimping operation.

Other characteristics, details and advantages of the invention can be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein:

FIG. 1a illustrates a heat exchanger in accordance with the prior art;

FIG. 1b illustrates a header-tank assembly of the heat exchanger of FIG. 1 a, wherein tabs of a header of the header-tank assembly are depicted in un-crimped configuration, also, is depicted an enlarged sectional view of the header-tank assembly along sectional plane X;

FIG. 1c illustrates a header-tank assembly of the heat exchanger of FIG. 1 a, wherein tabs of a header of the header-tank assembly are depicted in crimped configuration, also is depicted an enlarged sectional view of the header-tank assembly along sectional plane X;

FIG. 2a illustrates a heat exchanger in accordance with the present invention;

FIG. 2b illustrates a header-tank assembly of the heat exchanger of FIG. 2a , wherein tabs of a header of the header-tank assembly are depicted in un-crimped configuration, also is depicted an enlarged sectional view of the header-tank assembly along sectional plane Y;

FIG. 2c illustrates a header-tank assembly of the heat exchanger of FIG. 2a , wherein tabs of a header of the header-tank assembly are depicted in crimped configuration, also is depicted an enlarged sectional view of the header-tank assembly along sectional plane Y;

It must be noted that the figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention if needs be. The invention should however not be limited to the embodiment disclosed in the description.

Although, the present invention relates to a header of a heat exchanger used in automobiles that is configured with tabs of such configuration that facilitate crimping of the tank over the header, without requiring much effort and without damaging the crimping tool and also reducing the chances of damage, cracks and defects caused to the header due to the header being subjected to high crimping forces during crimping. Further, the header of the heat exchanger is of such configuration that even in case damage, cracks and defects are formed on the header, these are visible from outside and can be detected just by visual inspection. However, the present invention is applicable to any assembly used in any application and that is configured by crimping one part over the other.

FIG. 1a illustrates a conventional heat exchanger 01. The heat exchanger 01 generally includes a pair of spaced apart headers 02 a and 02 b, simply referred to as headers 02 a and 02 b connected to two distant and opposite end portions of a heat exchanger core received inside a housing 06. Specifically, each of the spaced apart headers 02 a and 02 b is configured with slots for receiving end portions of heat exchange tubes that configure the heat exchanger core along with the fins. Further, the headers 02 a and 02 b are also connected to the end portions of the housing 06 either by welding or brazing or any other joining process. The heat exchanger 01 further includes a pair of heat exchanger tanks 04 a and 04 b, hereinafter referred to as tanks, wherein each tank 04 a, 04 b is joined to the corresponding header 02 a, 02 b for configuring a sealed connection between the headers 02 a, 02 b and the corresponding tanks 04 a, 04 b, thereby forming a header-tank assembly 09 a, 09 b. Generally, the headers 02 a and 02 b are connected to the respective tanks 04 a and 04 b by crimping. The tank 04 a receives first heat exchanging fluid, often pressurized heat exchanging fluid from a first inlet 07 a and the other tank 04 b delivers out the first heat exchange fluid through a first outlet 07 b. The tanks 04 a and 04 b in conjunction with the corresponding headers 02 a and 02 b facilitate distribution of first heat exchange fluid to and collection of first heat exchange fluid from the heat exchange core 03. The housing 06 receives second heat exchange media, particularly coolant therein and around the heat exchange tubes through at least one second inlet. The second heat exchange media or coolant is delivered out of the housing 06 through at least one second outlet after the coolant has extracted heat from the first heat exchange fluid flowing through the heat exchange tubes.

Generally, the headers 02 a, 02 b of the header-tank assembly 09 a, 09 b are provided with tabs 03 a, 03 b respectively. The tabs 03 a, 03 b fold along the fold lines 08 a, 08 b for facilitating crimping of the headers 02 a, 02 b over respective foot portions 05 a, 05 b of the tanks 04 a, 04 b with sealing elements 11 a, 11 b disposed between the headers 02 a, 02 b and the respective foot portions 05 a, 05 b of the tanks 04 a, 04 b. FIG. 1b illustrates the header-tank assembly 09 a, 09 b of the heat exchanger 01, wherein the tabs 03 a, 03 b are depicted in un-crimped configuration, also is depicted an enlarged sectional view of the header-tank assembly 09 a, 09 b along sectional plane X with the tabs 03 a, 03 b in un-crimped configuration. FIG. 1c illustrates the header-tank assembly 09 a, 09 b of the heat exchanger 01, wherein the tabs 03 a, 03 b are depicted in crimped configuration, also is depicted an enlarged sectional view of the header-tank assembly 09 a, 09 b along sectional plane X with the tabs 03 a, 03 b in crimped configuration. The crimping between the headers 02 a, 02 b and the corresponding tanks 04 a, 04 b is required to be secure in order to configure leak-proof connection between the headers 02 a, 02 b and the corresponding tanks 04 a, 04 b. The sealing elements 11 a, 11 b provide sealing connection between the headers 02 a, 02 b and the respective tanks 04 a, 04 b. Generally, the headers 02 a, 02 b are formed of aluminum. In case the tabs 03 a, 03 b of the headers 02 a, 02 b are thick sectioned, comparative more crimping force is required for crimping the tabs 03 a, 03 b over the respective foot portions 05 a, 05 b of the tanks 04 a, 04 b. The higher crimping forces may damage the tabs 03 a, 03 b or the crimping tool used for crimping the tabs 03 a, 03 b configured on the headers 02 a, 02 b over the respective foot portions 05 a, 05 b of the tanks 04 a, 04 b.

In order to facilitate easy crimping of the tabs 03 a, 03 b configured on the headers 02 a, 02 b over the respective foot portions 05 a, 05 b of the tanks 04 a, 04 b, the tabs 03 a, 03 b may be weakened along the fold lines 08 a, 08 b by providing notches along inside wall of the tabs 03 a, 03 b as illustrated in FIG. 1 b. The tabs 03 a, 03 b with notches along inside wall thereof are comparatively more prone to cracks, defects and damages due to space restrictions. Also, if cracks or defects are formed along the notches due to crimping, these are not visible once the tabs 03 a, 03 b are crimped over the respective foot portions 05 a, 05 b of the tank 04 a, 04 b. Accordingly, such cracks and defects may go un-noticed and get aggravated over time resulting in mechanical failures, thereby reducing reliability and service life of the heat exchanger 01. Therefore, there is need of a heat exchanger with header 02 a, 02 b of such configuration that permits detection of damage, cracks and defects of the header 02 a, 02 b just by visual inspection, thereby avoiding severe mechanical failure of the heat exchanger 01 due to aggravation of the damage, cracks and defects because of these damages, cracks and defects remaining concealed and unnoticed.

FIG. 2a illustrates a heat exchanger 200 in accordance with an embodiment of the present invention. The heat exchanger 200 includes a pair of spaced apart header-tank assembly 100 a and 100 b connected by a plurality of heat exchanger elements 40 a that forms a part of a heat exchanger core 40 along with the fin elements disposed between the heat exchanger elements 40 a. A first header-tank assembly 100 a of the pair of header-tank assembly 100 a and 100 b facilitates distribution of heat exchange fluid to the heat exchanger elements 40 a, particularly, the heat exchanger tubes. A second header-tank assembly 100 b of the pair of header-tank assembly 100 a and 100 b disposed opposite to and spaced away from the first header-tank assembly 100 a facilitates collection of heat exchange fluid from the heat exchanger elements 40 a, particularly, the heat exchanger tubes.

The header-tank assembly 100 a is disclosed in accordance with an embodiment of the present invention. As the first and the second header-tank assemblies 100 a and 100 b are identical in structure, every embodiment disclosed henceforth for the header-tank assembly 100 a and the elements configuring the header-tank assembly 100 a may also applicable for the header-tank assembly 100 b and elements configuring the header-tank assembly 100. For sake of brevity of present document, the first header-tank assembly 100 a is only elaborately described in the below description.

The first header-tank assembly 100 a includes a tank 10 a, a header 20 a and a sealing element 30 a. The tank 10 a includes foot portions 12 a configured on at least one pair of opposite sides of the tank 10 a. The header 20 a includes tabs 22 a configured on at least one pair of opposite sides thereof. More specifically, the tabs 22 a are configured on the opposite sides of the header 20 a that are complimentary to the opposite sides of the tank 10 a on which the foot portions 12 a are configured. The tabs 22 a are crimped along fold lines 24 a configured thereon to receive the respective foot portions 12 a of the tank 10 a and configure connection between the header 20 a and the tank 10 a. In accordance with an embodiment of the present invention, at least one tab 22 a is configured on each side of at least one pair of opposite sides of the header 20. In one example, each side of the header 20 a includes three tabs configured thereon as illustrated in FIG. 2 b. In case there are more than one tab 22 a on each side of the at least one pair of opposite sides of the header 20 a, then the tabs 22 a are spaced apart from each other by spacing 23 a between the adjacent tabs 22 a as illustrated in FIG. 2b and FIG. 2 c. However, the present invention is not limited to any particular number, placement, spacing between the tabs 22 a as far as the tabs 22 a are capable of receiving the respective foot portions 12 a of the tank 10 a to configure connection between the header 20 a and the tank 10 a. The sealing element 30 a is disposed between the foot portions 12 a of the tank 10 a and the header 20 a and configures a sealing connection between the header 20 a and the tank 10 a. in accordance with an embodiment of the present invention, the sealing element 30 a is in form of a continuous closed loop. However, the present invention is not limited to any particular number, placement and configuration of the sealing element 30 a as far as the sealing element 30 a configures sealing connection between the header 20 a and the tank 10 a.

A notch 26 a is configured on an outside wall of each of the tabs 22 a configured on the header 20 a, wherein the notch 26 a extends along the fold lines 24 a to facilitate crimping of the tabs 22 a over the respective foot portions 12 a of the tanks 10 a, while still being visible even after the crimping operation. Specifically, the notches 26 a configured on the tabs 22 a facilitate weakening the tabs 22 a along fold lines to facilitate crimping of even thick sectioned tabs 22 a of the header 20 a over the foot portions 12 a of the respective tank 10 a along the fold lines 24 a. More specifically, the thickness of the tabs 22 a along the notch 26 a is reduced by 10-35 percent as compared to thickness of rest of the tabs 22 a. With such configuration and weakening of the tabs 22 a along the fold lines 24 a, comparatively less force is required for crimping of the tabs 22 a of the header 20 a over the foot portions 12 a of the respective tank 10 a, thereby reducing chances of damage to the tabs 22 a or the crimping tool used for crimping. Further, such configuration of the notches 26 a not only prevents formation of cracks or defects resulting due to crimping of the tabs 22 a of the header 20 a over the foot portion 12 a of the respective tank 10 a but also ensures quick detection of the cracks or defects just by visual inspection, in case the cracks or defects are formed as the cracks or defects are formed near the notches and at the exterior wall of the header 20 a. The tabs 22 a fold along the respective fold lines 24 a and the notches 26 a that are extending along top edges of the foot portions 12 a of the tank 10 a received in the respective header 20 a to define the crimped configuration of the tabs 22 a, The tabs 22 a in the crimped configuration thereof as illustrated in FIG. 2c , so receives the respective foot portions 12 a of the tank 10 a that a first portion 27 a and a second portion 28 a of the tabs 22 a connected along the notch 26 a abut against edges of the foot portions 12 a of the tank 10 a. In accordance with an embodiment, the edges of the foot portions 12 a of the tank 10 a are orthogonal to each other, accordingly, the first portion 27 a and the second portion 28 a of the tabs 22 a abutting against the orthogonal edges of the foot portions 12 a of the tank are also orthogonal. In another embodiment, the edges of the foot portions 12 a of the tank 10 a can be at any angle with respect to each other, accordingly, the first portion 27 a and the second portion 28 a of the tabs 22 a abutting against the edges of the foot portions 12 a of the tank 10 a are complementary to the edges. In accordance with an embodiment of the present invention, the notch 26 a extends along the length of each tab 22 a and along the fold line 24 a to facilitate crimping of the tabs 22 a over the respective foot portions 12 a.

Similar header-tank assembly 100 b, also referred to as the second header-tank assembly 100 b is configured at opposite end portion of the heat exchanger core 40, wherein the second tank 10 b of the header-tank assembly 100 b is crimped to the corresponding header 20 b. The header-tank assembly 100 b includes a tank 10 b, a header 20 b and a sealing element 30 b. The header 20 b includes tabs 22 b separated by spacing 23 b in case there are multiple tabs 22 b on a single side of the header 20 b. A notch 26 b is configured on an outside wall of each of the tabs 22 b, the notch 26 b extends along the fold line 24 b to facilitate crimping of the tabs 22 b over the respective foot portions 12 b while still being visible even after the crimping operation. The elements and function of the header-tank assembly 100 b are not elaborately disclosed in the present document for the sake of brevity of the present document.

Several modifications and improvement might be applied by the person skilled in the art to the heat exchanger and the header-tank assembly thereof as disclosed above and such modifications and improvements will still be considered within the scope and ambit of the present invention, as long as heat exchanger includes a pair of spaced apart header-tank assembly connected by a plurality of heat exchanger elements, wherein the header-tank assembly includes a tank, a header and a sealing element. The tank includes foot portions configured on at least one pair of opposite sides thereof. The header includes tabs configured on at least one pair of opposite sides. The tabs are crimped along fold lines configured thereon to receive respective foot portions of the tank and configure connection between the header and the tank. The sealing element is disposed between the foot portions of the tank and the header. A notch is configured on an outside wall of each tab, wherein the notch extends along the fold line to facilitate crimping of the tabs over the respective foot portions and is visible after crimping operation.

In any case, the invention cannot and should not be limited to the embodiments specifically described in this document, as other embodiments might exist. The invention shall spread to any equivalent means and any technically operating combination of means. 

1. A header-tank assembly comprising: a tank comprising foot portions configured on at least one pair of opposite sides thereof; a header comprising tabs configured on at least one pair of opposite sides thereof, the tabs adapted to be crimped along fold lines configured thereon to receive the respective foot portions of the tank and configure connection between the header and the tank; a sealing element disposed between the foot portions of the tank and the header, wherein a notch is configured on an outside wall of each tab, the notch extends along the fold line to facilitate crimping of the tabs over the respective foot portions.
 2. The header-tank assembly as claimed in claim 1, wherein at least one tab is configured on each side of at least one pair of opposite sides of the header.
 3. The header-tank assembly as claimed in claim 1, wherein the tabs configured on each side of at least one pair of opposite sides of the header are spaced apart from each other.
 4. The header-tank assembly as claimed in claim 1, wherein the tabs are adapted to fold along the respective fold lines and the notches extending along top edges of the foot portions of the tank received in the respective header to define the crimped configuration of the tabs of the headers.
 5. The header-tank assembly as claimed in claim 4, wherein the tabs in the crimped configuration thereof are adapted to receive the respective foot portions of the tanks such that a first portion and a second portion of the tabs connected along the notch abut against edges of the foot portions of the tank.
 6. The header-tank assembly as claimed in claim 1, wherein thickness of each tab along the notch is reduced by 10-35 percent as compared to the rest of the tab.
 7. A heat exchanger comprising a pair of spaced apart header-tank assembly and connected by a plurality of heat exchanger elements, wherein a first header-tank assembly is adapted to facilitate distribution of heat exchange fluid to the heat exchanger elements, whereas a second header-tank assembly disposed opposite to and spaced away from the first header-tank assembly is adapted to facilitate collection of heat exchange fluid from the heat exchanger elements, at least one of the header-tank assembly of the pair of header-tank assembly is according to claim
 1. 